Alpine ski boot with strap closure

ABSTRACT

An easy entry alpine ski boot includes one or more of a ladder strap closure, flap joint, ratcheting buckle and worm gear buckle.

PRIORITY CLAIM

This application claims the benefit of U.S. Provisional Pat. App. No. 61/187,380 filed Jun. 16, 2009 and entitled ALPINE SKIP BOOT WITH LADDER STRAP CLOSURE.

INCORPORATION BY REFERENCE

Each of U.S. Pat. Nos. 3,659,484, 3,679,031, 3,754,486, 4,240,309, 4,363,390, 5,549,429 and 6,654,987 is incorporated herein by reference in its entirety and for all purposes. In particular, the ratcheting mechanisms disclosed by these references are incorporated herein by reference in their entireties and for all purposes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an article of manufacture. In particular, a strap closure is combined with an alpine ski boot for securing the boot to a skier's foot.

2. Discussion of the Related Art

Alpine ski boots typically utilize lever type closures. While providing a mechanical advantage, these levers have nevertheless become increasingly difficult to operate due to, inter alia, the use of stiffer boot materials that must be conformed to the skier's foot and leg. It is often the case that a skier's physical capacity is challenged, and sometimes overcome, by the task of “cinching up” a modern, stiff, alpine ski boot.

FIG. 1A shows perspective view of a prior art alpine ski boot 100A having a plurality of lever type buckles 102 for cinching the boot. This design is typical of modern alpine ski boots. The boot has a throat 112 and a vamp 114 characterized by overlapping flaps 116, 118 providing a means for expanding the boot volume 110 to allow for a skier's foot to be inserted.

The lever buckles 101 include a rack 108 d fixed to the first flap 116 and a lever base 108 g fixed to a second flap 118. Typically made from rigid metallic material(s), the rack and base are fixed to the respective flaps by fasteners 108 e, 108 f such as metallic brads or rivets. A lever 108 a is pivotally mounted 108 b to the lever base and a bail coupled to the lever 108 c is drawn by a closing action of the lever toward the lever base. When the bail engages a tooth of the rack 115, closure of the lever draws the rack 108 d toward the lever base increasing the overlap of the flaps such that the inner volume of the boot 110 is reduced thereby tightening the boot on a skier's foot and leg.

FIG. 1B shows a side view another lever type buckle 100B. Unlike the stationary rack lever buckle of FIG. 1A, this buckle has a lever 134 incorporating a rack 120 such that the lever and rack pivot together when the lever is operated. In particular, the lever is pivotally mounted 118 b to the lever base 118 g which is fixed to a flap 130 of the boot. Fasteners 118 f, 128 similar to those described above are used. A bail base 126 is fixed to an opposing flap 132. The bail 122 is pivotally mounted 124 to the base. A hooking member near an end of the bail 123 engages the pivoting rack such that lever closure increases the overlap of the flaps thereby decreasing the inner volume of the boot 110 and tightening the boot on a skier's foot and leg. As before, this lever buckle also uses a rigid rack of limited length, depends on leverage limited by lever length, and has only limited capability to increase the overlap of the flaps.

SUMMARY OF THE INVENTION

Various embodiments of an alpine ski boot closure include one or more of a ladder strap, a coilable strap, a flap joint, a ratcheting buckle and a worm gear buckle. In an embodiment, a closure for an alpine ski boot comprises a boot outer shell including a plurality of flaps such as two or more sets of flaps. A boot vamp includes a first pair of opposed flaps of the plurality of flaps and a boot throat includes a second pair of opposed flaps of the plurality of flaps. For at least one pair of opposed flaps, a ladder strap is fixed to one flap and a buckle is fixed to the opposed flap. For the at least one pair of opposed flaps, a joint or similar means to ease spreading of the flaps is in at least one of the flaps. The flap joint is operable to reduce the force required to separate the ladder strap flap and the buckle flap of the at least one pair of opposed flaps, thereby easing the entry of a skier's foot into the boot. A ratcheting mechanism integral with the buckle is operable by a lever, or a similar means for increasing mechanical advantage, to advance the ladder strap through the buckle and to cinch the boot around the skier's foot and leg.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described with reference to the accompanying figures. These figures, incorporated herein and forming part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the relevant art to make and use the invention.

FIG. 1A is a perspective view of a prior art alpine ski boot.

FIG. 1B is a side view of a prior art alpine ski boot buckle.

FIGS. 2A and 2B are front views of an alpine ski boot in accordance with the present invention.

FIG. 3A is a side view of a first buckle for use with the boot of FIG. 2.

FIG. 3B is a perspective view of the buckle of FIG. 3A.

FIG. 4A is a first engagement mechanism for use with the boot of FIG. 2.

FIG. 4B is a second engagement mechanism for use with the boot of FIG. 2.

FIG. 4C is a third engagement mechanism for use with the boot of FIG. 2.

FIG. 5A is a side view of a second buckle for use with the boot of FIG. 2.

FIG. 5B is a perspective view of the buckle of FIG. 5A.

FIG. 6A is a side view of a third buckle for use with the boot of FIG. 2.

FIG. 6B is a perspective view of the buckle of FIG. 6A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The disclosure provided in the following pages describes examples of some embodiments of the invention. The designs, figures, and descriptions are non-limiting examples of certain embodiments of the invention. For example, other embodiments of the disclosed device may or may not include the features described herein. Moreover, disclosed advantages and benefits may apply to only certain embodiments of the invention and should not be used to limit the disclosed inventions.

In accordance with an embodiment of the present invention, FIG. 2A shows an alpine ski boot with multiple spread apart flaps 200A. Here, multiple opposed flaps 216 a-d, 218 a-b form part of the outer shell 230 of the boot (as shown). A liner 220 is fitted inside the shell and a tongue 222 is fitted inside the liner. FIG. 2B shows the boot of FIG. 2A with the flaps in an overlapping position tending to close the boot 200B.

Some embodiments have one or more “easy open” flaps; that is, flaps including features that reduce the force required to spread them apart. For example, given an outer shell material and geometry, multiple flap parts 216, 218 with gaps therebetween 232 reduce the forces required to spread the flaps to allow insertion of a skier's foot. In some embodiments, all or portions of the stiff plastic outer shell of conventional alpine ski boots is replaced with a more flexible material. In some embodiments, at least portions of the outer shell 230 are made from material(s) with flexural strengths in the range of about 1500 to 30,000 psi, the selected strength depending on the thickness used and the desired characteristics of the boot such as the skier's level of skill. In an embodiment, one or more flaps or flap portions are made from these more flexible materials. Suitable materials include polymers and combinations of polymers such as polyethylene, high density polyethylene and polyester plastics.

In an embodiment, one or more flaps 216 a-d, 218 a-b is coupled to the outer shell by a joint 250 that is relatively more flexible than an adjoining portion of the outer shell. In various embodiments, the joint is a plastic, a woven fabric such as nylon, a non-woven fabric such as a non-woven polypropylene fabric, a suitable synthetic material, a suitable natural material, or a combination of one or more of these materials. In some embodiments, the joint includes a pinned connection such as a hinge. In yet other embodiments, the joint is formed by thinning the parent material to reduce the stiffness relative to the adjoining material, for example, reducing the stiffness along a bending line. Persons of ordinary skill in the art will recognize that use of one or more of these or similar features reduce the forces required to spread the flaps as compared with a conventional alpine ski boot.

FIGS. 3A and 3B show a boot closure device used in some embodiments of the present invention 300A, 300B. Here, the closure device is in the form of a ladder strap with a ratcheting buckle. The ladder strap 308 is not a rigid rack like that used with lever type buckles 108 d, 120. Rather, it is made from a suitable flexible, high strength material such as plastic made from polyethylene, polyester or polyamide resins. Unlike the lever buckle 101, the ratcheting buckle 301 can, with increasing ladder strap length, accommodate increasingly larger flap closure gaps d1 a and/or smaller flap overlaps d1 b (see FIGS. 2A and 2B) without increasing the length of the lever 304.

A suitable fastener 312, such as one of the fasteners described above, passes through a hole in the strap 309 and couples the ladder strap 308 to a flap 314. When the free end of the strap 307 passes through the buckle housing 302, an engagement between a locking member supported by the buckle 306 and the strap prevents withdrawal of the strap absent user intervention. The buckle 301 is fixed to an opposing flap 316 by a suitable fastener 319 such as that used with the strap.

In an embodiment, the ratcheting lever 304 pivots on a shaft 303 extending between side walls of the buckle housing 302. Operation of the buckle's ratcheting lever 304 causes the ladder strap 308 to be advanced S1 through the buckle as rotating member(s) of the buckle (see FIGS. 4A and 4B) engage the teeth of the ladder strap 310 and advance the strap through the buckle 308. As shown in FIGS. 3A and 3B, the lever's free end 311 is opposed to the fixed end of the strap 313.

FIG. 4A shows an embodiment of a first ratchet mechanism appropriate for this arrangement 400A. The first ratchet mechanism includes a gear 404 having teeth 408 for engaging ladder strap teeth 310. In an embodiment, the gear shares an axis of rotation with the lever 304. The lever selectively engages the gear such that the gear is rotated in a counterclockwise direction 407 when the lever is rotated in a counterclockwise direction 410 by a force applied to the lever F. In an embodiment, the gear is held in place by an anti-rotation member 306 (see FIG. 3A) such as a pawl. Here, releasing the anti-rotation device allows the strap 308 to be loosened and/or withdrawn from the buckle. In some embodiments, a reversing pawl is included; in this case, selective use of the reversing pawl causes lever operation to accomplish both strap loosening and strap tightening. Mechanical advantage of the first ratchet mechanism increases as the useful length of the lever d3 increases and as the radius of the gear r1 decreases. And, in some embodiments, the buckle lever 304 includes a means for receiving an extension lever such as a hole 315. Here, an extension lever such as a rod 317 is inserted in the hole for increasing the mechanical advantage available to operate the buckle.

The selective engagement mechanism may be any suitable mechanism, such as a ratcheting or reversible ratcheting mechanism, know to persons of ordinary skill in the art. In various embodiments, one or more or portions of one or more of the selective engagement mechanisms described in U.S. Pat. Nos. 3,659,484, 3,679,031, 3,754,486, 4,240,309, 4,363,390 and 4,545,267 is used.

FIGS. 5A and 5B show a boot closure device used in some embodiments of the present invention 500A, 500B. The closure device is in the form of a ladder strap with a ratcheting buckle having compound gears. The ladder strap 308 is not a rigid rack like that used with lever type buckles 108 d, 120. Rather, it is made from a flexible material such as a suitable plastic including any of the strap materials mentioned above. Unlike the lever buckle 101, the ratcheting buckle 501 can, with increasing ladder strap length, accommodate increasingly larger flap closure gaps d1 a and/or smaller flap overlaps d1 b (see FIGS. 2A and 2B) without increasing the length d4 of the lever 504.

A suitable fastener 312, such as one of the fasteners described above, passes through a hole in the strap 309 and couples the ladder strap 308 to a flap 314. When the free end of the strap 307 passes through the buckle 501, an engagement between a locking member supported by the buckle 506 and the strap 308 prevents withdrawal of the strap absent user intervention. The buckle is fixed to an opposing flap 316 by a suitable fastener 519 such as that of the strap.

In an embodiment, the ratcheting lever 504 pivots on a shaft 503 extending between side walls of the buckle housing 502. Operation of the buckle's ratcheting lever 504 causes the ladder strap 308 to be advanced S2 through the buckle as rotating member(s) supported by the buckle (see FIG. 4B) engage and advance strap teeth 310. As shown in FIGS. 5A and 5B, the lever's free end 511 points toward the fixed end of the strap 313.

FIG. 4B shows an embodiment of a second ratchet mechanism appropriate for this arrangement 400B. The second ratchet mechanism 400B includes a gear 414 having a radius r2 and teeth 418. In an embodiment, the gear shares an axis of rotation 403 with a lever 504. A second gear 424 having a radius r3, an axis of rotation 413 and teeth 428 is driven by the first gear. The teeth of the second gear are also for engaging the teeth of the ladder strap 310. The lever 504 selectively engages the first gear such that the gear is rotated in a counterclockwise direction 417 when the lever is rotated in a counterclockwise direction 510 by a force applied to the lever F. In response, the second gear is rotated in the opposite direction (clockwise) 427.

In an embodiment, the gears are prevented from rotating by an anti-rotation member 506 such as a pawl. As discussed above, some embodiments include a reversing pawl. Mechanical advantage of this second ratchet mechanism increases as the useful length of the lever d3 increases and as a gear ratio (r3/r2) increases. And, in some embodiments, the buckle lever 504 includes a means for receiving an extension lever such as a hole 515. Here, an extension lever such as a rod 517 is inserted in the hole for increasing the mechanical advantage available to operate the buckle.

The selective engagement mechanism may be any suitable mechanism, such as ratcheting and reversible ratcheting mechanisms, know to persons of ordinary skill in the art. In various embodiments, one or more or portions of one or more of the selective engagement mechanisms described in U.S. Pat. Nos. 3,659,484, 3,679,031, 3,754,486, 4,240,309, 4,363,390 and 4,545,267 is used.

FIG. 4C shows another mechanism for use with ladder strap closures of some embodiments of the present invention 400C. Here, a worm-gear mechanism is used to move a ladder strap through a buckle. An interconnecting gear 438 is driven by a worm gear 439 and, in turn, drives the teeth 310 of a ladder strap 308. The worm gear is driven by a right angle drive gearbox 447 with an input shaft 462. In an embodiment, the right angle drive includes first and second mated bevel gears 448, 458 housed in the gearbox (as shown). The first shaft 462 has a coupling at one end 464 and the first bevel gear at the opposite end. A second shaft 441 interconnects the second bevel gear with the worm gear.

Clockwise rotation of the coupling 464 causes the worm gear to be turned and the ladder strap to move in a first direction S3. In similar fashion, anticlockwise rotation of the coupling causes the ladder strap to move in the opposite direction S4. In some embodiments, the gearbox 447 can be rotatably oriented about the x-x axis to allow more convenient access to the coupling point as might be needed for differently oriented buckles.

In some embodiments, the coupling is rotatable by a skier wearing the boot while the skier is standing in a substantially erect position. In one such embodiment, a ski pole 472 has a coupling 474 at or near its tip that mates with the right-hand drive coupling 464. After mating the couplings, the skier can operate the wormgear drive to tighten or loosen the ski boot by rotating the ski pole.

FIGS. 6A and 6B show a boot closure mechanism utilizing a coilable strap 600A, 600B. Here, the closure device is in the form of a thin, flexible strap and a selective engagement mechanism such as a ratcheting buckle for coiling the strap. The coilable strap 608 is not a rigid rack like that used with lever type buckles 108 d, 120. Rather, it is made from a suitable coilable, high strength material such as solid, woven, or non-woven plastics including polyethylene, polyester, or polyamide (including nylon) resins. Unlike the lever buckle 101, the ratcheting buckle 601 can, with increasing strap length, accommodate increasingly larger flap closure gaps d1 a and/or smaller flap overlaps d1 b (see FIGS. 2A and 2B) without increasing the length of the lever 604.

A suitable fastener 612, such as one of the fasteners described above, passes through a hole in the strap 609 and couples the ladder strap 608 to a flap 314. The buckle 601 is fixed to an opposing flap 316 by a suitable fastener 619 such as that of the strap.

In an embodiment, a ratcheting buckle includes a buckle housing 602, a shaft 603 supported by the buckle housing, ratcheting gears 616 fixed to the shaft, and a lever 604 for turning the shaft. A free end of the strap 607 is passed through a slit in the shaft 605 such that rotating the shaft causes the strap free end to be pressed and held against the shaft by the strap portion that is coiled atop the free end. Rotation of the shaft is caused by action of the buckle lever whose first end 628 pivots about the shaft. A ratcheting pawl of the lever 626 is urged by a first spring 627 into engagement with ratcheting gears 616 fixed at either end of the shaft such that clockwise operation of the lever engages the ratcheting pawl with leading gear tooth faces that are flat, turning the gears with the lever and spooling more of the strap 608 onto the shaft.

Anti-clockwise operation of the lever 604 readies the lever to turn the gears 616 again in another clockwise rotation. During anti-clockwise lever operation, the ratcheting pawl does not turn the gears 616 because trailing gear tooth faces are curved and serve to lift and disengage the ratcheting pawl by compressing the first spring 627. As the lever is rotated anti-clockwise about the shaft, the ratcheting pawl is repeatedly lifted to skip over adjacent gear teeth.

As with the ratcheting pawl of the lever 626, a locking pawl of the buckle housing 606 is similarly urged by a second spring 607 into engagement with the ratcheting gears 616. The locking pawl prevents unspooling of the strap when the ratcheting pawl is moving anti-clockwise with the lever or is otherwise disengaged from the ratcheting gears.

The selective engagement mechanism may be any suitable mechanism, such as ratcheting and reversible ratcheting mechanisms, know to persons of ordinary skill in the art. In various embodiments, one or more or one or more portions of the selective engagement mechanisms described in U.S. Pat. Nos. 5,549,429 and 6,654,987 is used.

As will be understood by persons of ordinary skill in the art, mechanical advantage of the ratchet mechanism increases as the useful length of the lever d13 increases. In some embodiments, the buckle lever 604 includes a means for receiving an extension lever such as a hole 615. Here, an extension lever such as a rod 317 is inserted in the hole for increasing the mechanical advantage available to operate the buckle.

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be apparent to those skilled in the art that various changes in the form and details can be made without departing from the spirit and scope of the invention. As such, the breadth and scope of the present invention should not be limited by the above-described exemplary embodiments, but should be defined only in accordance with the following claims and equivalents thereof. 

1. An easy entry alpine ski boot with a strap closure comprising: a boot outer shell including a plurality of flaps; a boot vamp including a first pair of opposed flaps of the plurality of flaps; a boot throat including a second pair of opposed flaps of the plurality of flaps; for at least one pair of opposed flaps, a strap fixed to one flap and a buckle fixed to the opposed flap; and, the buckle operable to advance the strap toward the buckle and to cinch the boot around the skier's foot and leg.
 2. The boot of claim 1 further comprising: teeth on the strap; and, the buckle for engaging the strap teeth.
 3. The boot of claim 2 further comprising: a ratchet mechanism integral with the buckle; and, the ratchet mechanism for tensioning the strap.
 4. The boot of claim 3 further comprising: a joint in at least one of the flaps of the at least one pair of opposed flaps; and, the flap joint operable to reduce the force required to separate the strap flap and the buckle flap of the at least one pair of opposed flaps thereby easing the entry of a skier's foot into the boot.
 5. The boot of claim 4 wherein the joint is a thinned section of the flap.
 6. The boot of claim 4 wherein the joint is a pinned hinge.
 7. The boot of claim 4 wherein gear teeth affixed to a buckle lever engage the ladder strap teeth.
 8. The boot of claim 7 further comprising: an extension rod; a buckle lever fitment adapted to engage the extension rod; and, the rod operable to operate the actuate the buckle lever.
 9. The boot of claim 2 further comprising: a worm-gear mechanism integral with the buckle; and, the worm-gear mechanism for tensioning the strap.
 10. The boot of claim 9 further comprising: a joint in at least one of the flaps of the at least one pair of opposed flaps; and, the flap joint operable to reduce the force required to separate the strap flap and the buckle flap of the at least one pair of opposed flaps thereby easing the entry of a skier's foot into the boot.
 11. The boot of claim 10 wherein the joint is a thinned section of the flap
 12. The boot of claim 10 wherein the joint is a pinned hinge.
 13. The boot of claim 12 further including: an extension rod; a worm gear mechanism fitment adapted to engage the extension rod; and, the rod operable to rotate the worm gear.
 14. The boot of claim 12 further including: a worm gear mechanism fitment adapted to receive a mating fitment; the mating fitment extending from a tip of an alpine ski pole; and, the ski pole operable to rotate the worm gear.
 15. The boot of claim 2 further comprising: a ratchet mechanism integral with the buckle; a rotatable shaft of the ratchet mechanism for coiling the strap; and, the rotatable shaft supported by a buckle housing.
 16. The boot of claim 15 further comprising: a joint in at least one of the flaps of the at least one pair of opposed flaps; and, the flap joint operable to reduce the force required to separate the strap flap and the buckle flap of the at least one pair of opposed flaps thereby easing the entry of a skier's foot into the boot.
 17. The boot of claim 16 wherein the joint is a thinned section of the flap.
 18. The boot of claim 17 wherein the joint is a hinge.
 19. The boot of claim 7 further comprising: an extension rod; a buckle lever fitment adapted to engage the extension rod; and, the rod operable to actuate the buckle lever.
 20. An easy entry alpine ski boot with a ladder strap closure comprising: a boot outer shell including a plurality of flaps; a boot vamp including a first pair of opposed flaps of the plurality of flaps; a boot throat including a second pair of opposed flaps of the plurality of flaps; for at least one pair of opposed flaps, a ladder strap fixed to one flap and a buckle fixed to the opposed flap; a joint in at least one of the flaps of the at least one pair of opposed flaps; the flap joint operable to reduce the force required to separate the ladder strap flap and the buckle flap of the at least one pair of opposed flaps thereby easing the entry of a skier's foot into the boot; a ratcheting mechanism integral with the buckle; and, the ratcheting mechanism operable by a lever to advance the ladder strap through the buckle and cinch the boot around the skier's foot and leg.
 21. An easy entry alpine ski boot with a ladder strap closure comprising: a boot outer shell including a plurality of flaps; a boot vamp including a first pair of opposed flaps of the plurality of flaps; a boot throat including a second pair of opposed flaps of the plurality of flaps; for at least one pair of opposed flaps, a ladder strap fixed to one flap and a buckle fixed to the opposed flap; a joint in at least one of the flaps of the at least one pair of opposed flaps; the flap joint operable to reduce the force required to separate the ladder strap flap and the buckle flap of the at least one pair of opposed flaps thereby easing the entry of a skier's foot into the boot; a worm gear mechanism including an angular drive integral with the buckle; and, a ski pole adapted to mate with the worm gear mechanism for rotating the worm gear, advancing the ladder strap through the buckle, and cinching the boot around the skier's foot and leg.
 22. An easy entry alpine ski boot with a coilable strap closure comprising: a boot outer shell including a plurality of flaps; a boot vamp including a first pair of opposed flaps of the plurality of flaps; a boot throat including a second pair of opposed flaps of the plurality of flaps; for at least one pair of opposed flaps, a coilable strap fixed to one flap and a buckle fixed to the opposed flap; a joint in at least one of the flaps of the at least one pair of opposed flaps; the flap joint operable to reduce the force required to separate the coilable strap flap and the buckle flap of the at least one pair of opposed flaps thereby easing the entry of a skier's foot into the boot; a ratcheting mechanism integral with the buckle; the ratcheting mechanism including a ratcheting pawl and a locking pawl; and, the ratcheting mechanism operable via a lever to coil the coilable strap on a rotatable shaft within the buckle and cinch the boot around the skier's foot and leg.
 23. A method enabling a skier to cinch his/her alpine ski boot while standing erect comprising the steps of: providing a boot outer shell including a plurality of flaps, a boot vamp including a first pair of opposed flaps of the plurality of flaps, and a boot throat including a second pair of opposed flaps of the plurality of flaps; for at least one pair of opposed flaps, fixing a ladder strap to one flap and fixing a buckle to the opposed flap; providing a joint in at least one of the flaps of the at least one pair of opposed flaps; easing the entry of the skier's foot into the boot by reducing the force required to separate the ladder strap flap and the buckle flap of the at least one pair of opposed flaps by providing a joint in at least one of the flaps of the at least one pair of opposed flaps; providing a worm gear mechanism integral with the buckle; providing a ski pole adapted to mate with the worm gear mechanism; mating the ski pole and worm gear mechanism; and, the skier, while standing erect, rotating the ski pole to advance the ladder strap through the buckle to cinch the boot around the skier's foot and leg. 